Semiconductor devices and structures thereof

ABSTRACT

A structure having air gaps between interconnects is disclosed. A first insulating material is deposited over a workpiece, and a second insulating material having a sacrificial portion is deposited over the first insulating material. Conductive lines are formed in the first and second insulating layers. The second insulating material is treated to remove the sacrificial portion, and at least a portion of the first insulating material is removed, forming air gaps between the conductive lines. The second insulating material is impermeable as deposited and permeable after treating it to remove the sacrificial portion. A first region of the workpiece may be masked during the treatment, so that the second insulating material becomes permeable in a second region of the workpiece yet remains impermeable in the first region, thus allowing the formation of the air gaps in the second region, but not the first region.

This is a divisional application of U.S. application Ser. No.11/151,134, entitled, “Methods of Manufacturing Semiconductor Devicesand Structures Thereof,” which was filed on Jun. 13, 2005 now U.S. Pat.No. 7,629,225 and is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to the fabrication ofsemiconductor devices, and more particularly to the formation ofinsulating materials of interconnect layers.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as computers, cellular phones, personal computing devices, and manyother applications. Home, industrial, and automotive devices that in thepast comprised only mechanical components now have electronic parts thatrequire semiconductor devices, for example.

Semiconductor devices typically include several layers of insulating,conductive and semiconductive materials that are patterned to formintegrated circuits (ICs). There may be a plurality of transistors,memory devices, switches, conductive lines, diodes, capacitors, logiccircuits, and other electronic components formed on a single die orchip. Semiconductor technology has experienced a trend towardsminiaturization, in order to meet the demands of product size reduction,improved device performance, and reduced power requirements in the endapplications that semiconductors are used in, for example.

In the past, integrated circuits contained only a relatively smallnumber of devices per chip, and the devices could be easilyinterconnected. However, in more recent integrated circuit designs,there may be millions of devices on a single chip, resulting in the needfor multilevel interconnect systems, wherein the area for interconnectlines is shared among two or more material levels.

The manufacturing process for semiconductor devices is typicallyreferred to in two phases: the front-end-of-line (FEOL) and theback-end-of-line (BEOL). The FEOL is defined as the process steps thatbegin with a starting wafer up to the formation of the firstmetallization layer, and the BEOL is defined as all process steps fromthat point forward. The interconnect lines of an integrated circuit areusually formed in the BEOL.

As the minimum line width on an integrated circuit becomes smaller, theactive device density increases, and transistor switching speeddecreases, while signal propagation delays in the interconnect systembecome limiting on the performance of the integrated circuit. Also, asthe chip size increases, the interconnect path lengths also increase.Thus, many large ultra-large scale integration (ULSI) integratedcircuits are limited by interconnect propagation delay time.

The propagation delay of integrated circuits becomes limited by the RCdelay of the interconnection lines when the minimum feature size isdecreased below about 0.25 μm for example, which limits the circuitspeeds. The RC delay refers to the resistance of the conductive linesused for the interconnect and the capacitance between the conductivelines.

One challenge in the semiconductor industry is to reduce and minimizethe RC delay of integrated circuits, in order to improve deviceperformance and increase device speed. The resistive or R component ofRC delay is being addressed by the move from the use of aluminum tocopper, which has a lower resistance than aluminum, as the material ofconductive lines. The C or capacitive component of RC delay is beingaddressed by attempts to use insulating materials between the conductivelines that comprise a lower dielectric constant (k) than materials suchas SiO₂ that were used in the past for inter-metal dielectric (IMD)materials.

What are needed in the art are improved methods of lowering thecapacitive component C of the RC delay in integrated circuits.

SUMMARY OF THE INVENTION

These and other problems are generally solved or circumvented, andtechnical advantages are generally achieved, by preferred embodiments ofthe present invention, which provide novel methods of forming air gapsbetween conductive lines of semiconductor devices and structuresthereof.

In accordance with a preferred embodiment of the present invention, amethod of manufacturing a semiconductor device includes providing aworkpiece, forming a plurality of conductive lines over the workpiece,disposing a first insulating material over the workpiece, and disposinga second insulating material over the first insulating material. Thefirst insulating material is disposed between the plurality ofconductive lines. The second insulating material is disposed between theplurality of conductive lines and comprises a sacrificial portion. Thesecond insulating material is treated to remove the sacrificial portionof the second insulating material, and at least a portion of the firstinsulating material is removed, forming air gaps between the pluralityof conductive lines.

In accordance with another preferred embodiment of the presentinvention, a method of manufacturing a semiconductor device includesproviding a workpiece, disposing a first insulating material over theworkpiece, and disposing a second insulating material over the firstinsulating material. The second insulating material has a top surfaceand comprises a sacrificial portion. The second insulating material andthe first insulating material are patterned, and a conductive materialis disposed over the patterned second insulating material and the firstinsulating material. The conductive material is removed from over thetop surface of the second insulating material, leaving conductivematerial within the patterned first and second insulating material. Thesecond insulating material is treated to remove the sacrificial portionof the second insulating material, and at least a portion of the firstinsulating material is removed.

In accordance with yet another preferred embodiment of the presentinvention, a semiconductor device includes a workpiece, the workpiececomprising a first region and a second region, and a plurality ofconductive lines formed over the workpiece, the plurality of firstconductive lines having a top region. A first insulating material isdisposed between the plurality of first conductive lines proximate thetop region of the plurality of first conductive lines, the firstinsulating material being impermeable in the first region and permeablein the second region. A second insulating material is disposed beneaththe first insulating material between the plurality of first conductivelines in the first region. Air gaps are disposed beneath the firstinsulating material between the plurality of first conductive lines inthe second region.

Advantages of preferred embodiment of the present invention includeproviding novel methods of forming air gaps between conductive features.Air gaps having a predictable shape over a wide range of spaces betweenconductive lines are created. No additional topography is introduced tothe semiconductor device, and few additional processing steps arerequired. In one embodiment, air gaps are formed between conductivefeatures in critical areas, but not in non-critical areas, where the RCdelay is not an issue. Because some regions of the workpiece do not havethe air gaps disposed therein, the insulating material in those regionsprovides strong structural support and mechanical strength for theintegrated circuit. The top layer of insulating material having thesacrificial portion is impermeable as deposited, preventingcontamination of the various material layers during thechemical-mechanical polish procedure to remove excess conductivematerial from the top surface of the top layer of insulating material.

The foregoing has outlined rather broadly the features and technicaladvantages of embodiments of the present invention in order that thedetailed description of the invention that follows may be betterunderstood. Additional features and advantages of embodiments of theinvention will be described hereinafter, which form the subject of theclaims of the invention. It should be appreciated by those skilled inthe art that the conception and specific embodiments disclosed may bereadily utilized as a basis for modifying or designing other structuresor processes for carrying out the same purposes of the presentinvention. It should also be realized by those skilled in the art thatsuch equivalent constructions do not depart from the spirit and scope ofthe invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIGS. 1 through 4 show cross-sectional views of a prior art method offorming air gaps at various stages of manufacturing that requires a highdielectric constant cap layer for stability;

FIG. 5 shows another prior art conductive line structure with air gaps,wherein a topography is created in widely-spaced conductive lineregions, which has a detrimental effect on lithography processes;

FIGS. 6 through 11 show cross-sectional views of a method of forming airgaps at various stages of manufacturing in accordance with a preferredembodiment of the present invention, wherein a sacrificial portion of asecond insulating material is removed so that a first insulatingmaterial may be removed through the second insulating material to formthe air gaps;

FIGS. 12 and 13 show another embodiment of the present invention,wherein the air gaps are formed in closely-spaced regions of aninterconnect layer, but not widely-spaced regions; and

FIG. 14 shows another embodiment of the present invention, wherein aconductive cap layer is selectively formed on the top surface ofconductive features after forming the air gaps.

Corresponding numerals and symbols in the different figures generallyrefer to corresponding parts unless otherwise indicated. The figures aredrawn to clearly illustrate the relevant aspects of the preferredembodiments and are not necessarily drawn to scale.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of the presently preferred embodiments arediscussed in detail below. It should be appreciated, however, that thepresent invention provides many applicable inventive concepts that canbe embodied in a wide variety of specific contexts. The specificembodiments discussed are merely illustrative of specific ways to makeand use the invention, and do not limit the scope of the invention.

The capacitance C in the RC delay of BEOL interconnects may be loweredby the use of low-k materials. For example, silicon dioxide (SiO₂),commonly used as an interconnect insulating material in the past, has adielectric constant k of about 4.1 or 4.2. A dense low-k material mayhave a k value of about 2.8, for example, whereas a porous low-kmaterial may have a k value of about 2.2, for example. However, loweringthe dielectric constant to a value lower than about 2.2 is difficult,because the porosity of the insulating materials becomes larger as thedielectric constant decreases; thus, the low k insulating materialbecomes weaker.

Theoretically, air is an ideal dielectric, having a dielectric constantof 1.0. However, a problem with using air as an insulating materialbetween conductive lines is that the structure can easily collapse undermechanical stress, e.g., during further manufacturing processing,testing, packaging, or transportation, destroying the integratedcircuit. An interconnect system needs to be workable, reliable, andmechanically stable, so that the chip can be manufactured and packaged,for example.

Thus, integration schemes for introducing air between conductive lineswithout collapsing the interconnect structure, and for manufacturing aninterconnect system having air gaps between conductive lines that doesnot easily collapse, are needed in the art.

Prior art methods of forming air gaps include forming air gaps incopper/low dielectric constant integration schemes using sacrificialfilms or template films, as described by John Sudijono in a presentationat IEDM 2004—Short Course entitled, “45 nm BEOL,” p. 43, which isincorporated herein by reference. However, there are disadvantages inthese prior art methods. Sacrificial films and templates tend to formpinch-offs on the top of the copper lines, forming triangular-shaped airgaps and increasing the dielectric constant.

Another prior art method of forming air gaps is forming air gaps usingdecomposable polyoxymethylene (POM), as described by John Sudijono in apresentation at IEDM 2004—Short Course entitled, “45 nm BEOL,” p. 44,which is incorporated herein by reference. FIGS. 1 through 4 showcross-sectional views of this prior art method of forming air gaps atvarious stages of manufacturing.

Referring first to FIG. 1, in this method of forming air gaps, asacrificial material 104 comprising POM is deposited over a workpiece102 that comprises a semiconductor wafer. A hard mask 106 is depositedover the sacrificial material 104. The hard mask 106 is patterned, andthe hard mask 106 is used as a mask for the patterning of thesacrificial material 104. Shown in FIG. 2, a barrier seed layer 108 isformed over the patterned hard mask 106 and sacrificial material 104,and copper 110 is formed over the barrier seed layer 108 by plating. Achemical-mechanical polish process is used to remove the copper 110 andhard mask 106 from over the sacrificial material 104, as shown in FIG.3. The copper 110 and barrier seed layer 108 comprise conductive linesin the interconnect structure.

A dielectric layer 112 is then deposited over the conductive lines108/110 and the sacrificial layer material 104, as shown in FIG. 3. Thesacrificial material 104 is then decomposed by exposing the workpiece102 to high temperature and pressure, leaving air gaps 114 formedbetween the conductive lines 108/110 beneath the dielectric layer 112,as shown in FIG. 4.

A problem with the prior art method and semiconductor device 100 shownin FIGS. 1 through 4 is that because low k dielectric materials areporous and structurally weak, the dielectric layer 112 comprises SiN orSiON, which have a high dielectric constant, e.g., greater than thedielectric constant of silicon dioxide. A low k dielectric materialcannot be used for the dielectric layer 112 because that would introducean instability problem and cause problems with CMP processes forlater-deposited material layers. Thus, because a high k material, whichmay be relatively thick in some prior art applications, must be used forthe overlying dielectric layer 112, the beneficial effects of the airgaps 114 between the conductive lines 108/110 are negated.

FIG. 5 shows another prior art conductive line structure with air gaps,wherein a topography is created in widely-spaced conductive lineregions, which has a detrimental effect on lithography processes. Inthis approach, the workpiece 102 has regions where closely-spacedconductive lines 110 are formed in region 120 and where widely-spacedconductive features 110 are formed in region 122. A thin cap layer 124is formed over air gaps 114 between the closely-spaced conductive lines110 in region 120, as shown. The thin cap layer 124 may comprise SiN orSiON or other materials that provide structural support, for example.The air gaps 114 may be formed using the method described with referenceto FIGS. 1 through 4, for example. The air gaps 114 are not typicallyneeded in the region 122 having widely-spaced conductive lines 110,because the dielectric constant of the dielectric material is not aproblem in that region 122, for example.

Because the thin cap layer 124 is deposited by chemical vapor deposition(CVD), it is conformal, and thus forms conformally on the widely-spacedconductive lines 110 in region 122, as shown. The depressions 126 in thetopography of the semiconductor device are a problem in lithographyprocesses, and decrease the depth of focus, for example, in thepatterning of subsequently-deposited material layers (not shown). Thus,the size of features in subsequently-patterned material layers must beincreased, because of the limitations in the lithography processingcaused by the topography of the structure.

In other prior art methods of forming air gaps, a permeable material isdeposited over a material that will be sacrificially removed. During thedamascene formation of conductive lines, the permeable material allowscontaminants from the CMP process to enter the permeable material andpossibly even reach the sacrificial material. The contamination, such asthe uptake of water and chemicals used in polishing or cleaning oradhesion of slurry particles or CMP byproducts, can lead tocross-contamination, a change in the value of the dielectric constantbetween conductive lines, and can cause reliability issues.

Thus, what are needed in the art are improved methods of forming airgaps between conductive features that do not require a high dielectricconstant cap layer, do not introduce topography to the structure, andthat protect underlying material layers from contaminants in the CMPprocesses and cleaning processes.

Embodiments of the present invention achieve technical advantages byproviding methods of forming air gaps between interconnects ofintegrated circuits and structures thereof. A first insulating materialis deposited over a workpiece, and a second insulating material having asacrificial portion is deposited over the first insulating material.Conductive lines are formed in the first and second insulating layers.The second insulating material is treated to remove the sacrificialportion, and at least a portion of the first insulating material isremoved, forming air gaps between the conductive lines. The secondinsulating material is impermeable as deposited, and permeable aftertreating it to remove the sacrificial portion.

In one embodiment, a first region of the workpiece may be masked duringthe treatment, so that the second insulating material becomes permeablein a second region of the workpiece yet remains impermeable in the firstregion, thus allowing the formation of air gaps in the second region,but not the first region. In this embodiment, the air gaps arepreferably formed in areas of the chip where a low-k material is mostbeneficial, for example. In areas of the chip where the RC delay is notas critical, air gaps are preferably not formed. Thus, the regions nothaving air gaps provide a high mechanical strength for the interconnectstructure, resulting in an integrated circuit with air gaps that has astable structure.

Several methods of manufacturing integrated circuits in accordance withpreferred embodiments of the present invention will be described herein.The present invention will be described with respect to preferredembodiments in a specific context, namely a semiconductor device havinga single layer of interconnect. The invention may also be applied,however, to semiconductor devices having multiple layers ofinterconnect. For example, the air gaps may be formed in one or moreinterconnect layers of a semiconductor device. Also, in the figures, theconductive lines are formed using a damascene process; however,embodiments of the present invention also have application insemiconductor devices wherein conductive lines are formed usingsubtractive etch processes, for example.

FIGS. 6 through 11 show cross-sectional views of a method of forming airgaps at various stages of manufacturing in accordance with a preferredembodiment of the present invention, wherein a sacrificial portion of asecond insulating material is removed so that a first insulatingmaterial may be removed through the second insulating material to formair gaps. With reference to FIG. 6, a semiconductor device 200 is shown.The semiconductor device 200 comprises a workpiece 202. The workpiece202 may include a semiconductor substrate comprising silicon or othersemiconductor materials that may be covered by an insulating layer, forexample. The workpiece 202 may include active components or circuitsformed in the FEOL, not shown. The workpiece 202 may comprise siliconoxide over single-crystal silicon, for example. The workpiece 202 mayinclude other conductive layers or other semiconductor elements, e.g.transistors, diodes, etc. Compound semiconductors, GaAs, InP, Si/Ge, orSiC, as examples, may be used in place of silicon.

A first insulating material 230 is formed over the workpiece 202. Thefirst insulating material 230 preferably comprises a sacrificialmaterial that is removable by reactive ion etch (RIE), anneal, or iseasily decomposable at higher temperatures, in accordance withembodiments of the present invention. The first insulating material 230preferably comprises an organic polymer such as polynorbornene, asexamples, although alternatively, the first insulating material 230 maycomprise other organic polymers or other materials. The first insulatingmaterial 230 may be deposited by a spin-on process, physical vapordeposition (PVD), or CVD, as examples, although alternatively, the firstinsulating material 230 may be deposited using other methods. The firstinsulating material 230 preferably comprises a thickness d₁ of about2,000 Angstroms or less, and more preferably, comprises a thickness ofabout 1,000 Angstroms, as examples, although alternatively, the firstinsulating material 230 may comprise other dimensions.

A second insulating material 232 is formed over the first insulatingmaterial 230. The second insulating material 232 preferably comprises athickness d₂ that is less than the thickness d₁ of the first insulatingmaterial 230, in one embodiment. The thickness d₂ preferably comprisesabout 600 Angstroms or less, and more preferably comprises a thicknessof about 200 to 500 Angstroms, as examples, although alternatively, thesecond insulating material 232 may comprise other dimensions. Thethickness d₁ of the first insulating material 230, of which at least aportion will be removed, is preferably as thick as possible, to achievethe lowest possible dielectric constant when the air gaps 242 (see FIG.11) are formed in the structure, for example. The second insulatingmaterial 232 and the first insulating material 230 comprise aninter-level dielectric (ILD) layer, in one embodiment, for example.

The thicknesses d₁ and d₂ of the first and second insulating materials230 and 232, respectively, depends on the thickness of the conductivelines 210 that will be formed, to be described further herein. Inaccordance with embodiments of the present invention, it is desirable toachieve a good compromise between maximum air gap volume (e.g., which isdetermined by the thickness d₁ of the first insulating material 230) andstructural stability (which is a function of the thickness d₂ of thesecond insulating material 232). A thickness d₁ of the first insulatingmaterial 230 of about 66-75% of the conductive line 210 thickness, and athickness d₂ of the second insulating material 232 of about 34-25% ofthe conductive line 210 thickness, are preferred thicknesses d₁ and d₂of the first and second insulating materials 230 and 232, in someembodiments, for example. However, in other embodiments, the thicknessd₂ may be about 40-50% of the conductive line 210 thickness, e.g., ifthe second insulating material 232 is made permeable by converting apolymer with lower Si content into a SiO₂-type skeleton/mesh structurevia an O₂ treatment, for example, to be described further herein.

A portion of the second insulating material 232 preferably comprisesSiCO, an organic polymer such as polyoxymethylene that is relativelyvolatile when exposed to a heat treatment, or SiO₂, as examples,although alternatively, the second insulating material 232 may compriseother organic polymers or other materials. The second insulatingmaterial 232 may be deposited by a spin-on process, PVD, or CVD, asexamples, although alternatively, the second insulating material 232 maybe deposited using other methods.

The second insulating material 232 is preferably impermeable asdeposited, in accordance with an embodiment of the present invention.The second insulating material 232 preferably comprises a sacrificialportion that will later be removed, to be described further herein.

Next, a damascene process is used to form conductive lines within thesecond insulating material 232 and the first insulating material 230.The second insulating material 232 and the first insulating material 230are patterned with a desired pattern for conductive lines, as shown inFIG. 7. For example, a photoresist (not shown) and an optional hard mask(also not shown) are deposited over the second insulating material 232,and the photoresist is patterned. The photoresist is used as a maskwhile exposed portions of the second insulating material 232 and thefirst insulating material 230 are etched away, or, if a hard mask isused, the photoresist is used as a mask to pattern the hard mask, thephotoresist is removed, and the hard mask is used as a mask whileexposed portions of the second insulating material 232 and firstinsulating material 230 are etched away. The workpiece 202 and/orpattern may include a first region 220 of closely-spaced conductivelines and a second region 222 of widely-spaced conductive lines, asshown. The distance between the conductive lines in the second region222 may be about 2 times or greater than the distance between theconductive lines in the first region 220, for example.

A conductive material 210 is deposited over the patterned secondinsulating material 232 and the first insulating material 230, as shownin FIG. 7. The conductive material 210 preferably comprises copper,aluminum, alloys thereof, or other conductive materials or combinationsof materials. One or more barrier layers, liners, and/or seed layers(not shown) may be formed over the exposed portion of the workpiece 202and the patterned second insulating material 232 and the firstinsulating material 230 before depositing the conductive material 210,for example. If the conductive material 210 comprises copper, which hasa high diffusion rate, preferably one or more barrier layers are used toprevent the copper from diffusing into adjacent material layers, forexample. The conductive material 210 fills in the patterns in the secondinsulating material 232 and the first insulating material 230, and alsoresides over the top surface of the second insulating material 232, asshown in FIG. 7.

Next, a CMP process and/or etch process is used to remove the conductivematerial 210 from the top surface of the second insulating material 232and form conductive lines 210 in the second insulating material 232 andthe first insulating material 230, leaving the structure shown in FIG.8. The conductive lines 210 are also referred to herein as conductivefeatures, for example. The second insulating material 232 preferablycomprises a material that is adapted to protect the first insulatingmaterial 230 from contaminants that the workpiece 202 is exposed toduring the CMP process and cleaning processes that may follow the CMPprocess, for example. Because the second insulating material 232 ispreferably impermeable as deposited, advantageously, the secondinsulating material 232 protects the first insulating material 230 frompossible contamination; e.g., from uptake of water and chemicals inpolishing or cleaning steps, adhesion of slurry particles or CMPby-products, which could possibly lead to cross-contamination and/orchange in the dielectric constant (k) value, or cause reliabilityissues, as examples.

In accordance with preferred embodiments of the present invention, thesecond insulating material 232 is treated with a treatment 234 to removethe sacrificial portion 236 of the second insulating material 232, asshown in FIG. 8. The treatment 234 may comprise a RIE or an annealprocess, for example. The exposed top surfaces of the conductive lines210 are preferably not deleteriously affected by the treatment 234.

In one embodiment, the sacrificial portion 236 that is removed comprisesportions of the second insulating material 232. In this embodiment, thetreatment 234 comprises a RIE that is used to pattern the secondinsulating material 232 with a plurality of apertures 238. A mask may beused to pattern the second insulating material 232, e.g., by depositinga photoresist, patterning the photoresist, and using the photoresist asa mask during the etch process for the second insulating material 232.The second insulating material 232 preferably comprises SiCO, SiO₂, orpolyoxymethylene in this embodiment, as examples, althoughalternatively, the second insulating material 232 may comprise othermaterials.

The plurality of apertures 238 is preferably very small, and maycomprise a minimum feature size of the semiconductor device 200, forexample. In some embodiments, very small aperture 238 sizes in thesecond insulating material 232 may be created lithographically by theapplication of so-called “shrink methods,” such as a resist reflowprocess, or by the use of products such as RELACS™ by MitsubishiElectric Corporation, or CARL™ by Siemens Aktiengesellschaft. In aresist reflow process, a patterned layer of contact holes in resist issubjected to a heat treatment until the resist starts to flow, whichleads to shrinkage of the bottom critical dimension (CD) of the holes,for example. These shrink methods advantageously allow minimum aperture238 sizes to be formed that are smaller than the inherent resolutioncapability of the optical system, for example. The chemical or reflowbias of these methods may be exceeded beyond the generally used range(e.g., about 30-40 nm/edge) at the expense of reduced process control.However, advantageously, in the application of embodiments of thepresent invention, there is relaxed CD control required, in comparisonto routine lithography applications, for example, and such shrinkmethods may thus be utilized to form the apertures 238.

In another embodiment, the sacrificial portion 236 comprises asacrificial component of the second insulating material 232 that isheat-sensitive. In this embodiment, the treatment to remove thesacrificial portion 236 of the second insulating material 232 maycomprise an anneal process or heat treatment. For example, the treatment234 may comprise an anneal process at a temperature of about 300 to 400degrees C. for about 0.5 to 60 minutes, wherein the anneal process isadapted to remove the heat-sensitive component of the second insulatingmaterial 232, e.g., the sacrificial component 236, although othertemperatures and times may be used.

If the second insulating material 232 comprises SiCO, then theheat-sensitive component 236 may comprise C, and the treatment 234causes the C to leave the second insulating material 232, for example.Alternatively, if the second insulating material 232 comprises anorganic polymer, the heat-sensitive component 236 may comprisepolynorbornene or other materials, as examples. When the heat-sensitivecomponent 236 leaves the second insulating material 232, pores 238 areformed in the second insulating material 232, as shown in FIG. 9.

Thus, removing the sacrificial portion 236 of the second insulatingmaterial 232 using the treatment 234 comprised of either a RIE or heattreatment preferably results in the formation of pores or apertures 238in the second insulating material 232 in accordance with embodiments ofthe present invention, as shown in FIG. 9. The second insulatingmaterial 232 shown in FIG. 8 is changed after the treatment 234 and isrepresented by 232′ in FIGS. 9 through 11, for example. In particular,the second insulating material 232′ includes apertures or pores 238 thatwere not present in the second insulating material 232 as deposited;thus, the second insulating material 232′ is permeable after thetreatment 234. For example, the second insulating material 232′ isadapted to allow liquids or gases to pass through the pores or apertures238.

Preferably, the second insulating material 232′ is permeable to theextent that at least a portion of the first insulating material 230 orall of the first insulating material 230 may pass through the pores orapertures 238 of the second insulating material 232′. If aheat-sensitive component of the second insulating material 232 wasremoved during the treatment 234, then the second insulating material232′ shown in FIGS. 9 through 11 is absent at least a portion of theheat-sensitive component of the second insulating material 232 asdeposited, for example.

Next, at least a portion of the first insulating material 230 is removedthrough the pores or apertures 238 in the second insulating material232, as shown in FIG. 10, forming air gaps 242 between the conductivelines 210 beneath the second insulating material 232′, as shown in FIG.11. This may be accomplished by another treatment process 240 comprisinga RIE or heating process, for example, as shown in FIG. 10. Preferably,if a RIE is used to remove the first insulating material 230, the secondinsulating material 232 comprises a material that is adapted not to beetched away by the RIE process to remove the first insulating material230, for example. If an anneal process is used to remove the firstinsulating material 230, then the anneal process may comprise atemperature of about 400 degrees C. or greater for about 0.5 to 60minutes, as an example, although other temperatures and times may beused.

Next, five examples of combinations of materials and preferred methodsof processing the first insulating material 230 and the secondinsulating material 232 in accordance with embodiments of the presentinvention will be described. In a first material combination example,the first insulating material 230 preferably comprisesnon-photosensitive fine chemicals (NFC) by JSR Micro, Inc., which is anaromatic hydrocarbon-based spin-on material also known as a BEOLmaterial that is spun-on and baked. The first insulating material 230may also comprise BLACK DIAMOND™ by Applied Materials, Inc., which is alow dielectric constant material that may be deposited by CVD. Thesecond insulating material 232 preferably comprises a spin-on-glass thatis spin coated and hard-baked, e.g., at a temperature of about 350degrees C. The second insulating material 232 is then lithographicallypatterned (this comprises the treatment 234 in this embodiment) withsmall apertures 238 using a shrink method such as reflow, RELACS™ orCARL™. The first insulating material 230 is then removed using O₂plasma, and optionally also using heat assistance, e.g., by elevatingthe temperature to about 100 to 300 degrees C. This material selectionfor the first and second insulating materials 230 and 232, respectively,is advantageous in that the first insulating material 230 iscarbonaceous, yet the second insulating material 232 is carbon-free, forexample.

In a second material combination example, the first insulating material230 preferably comprises polynorbornene. The second insulating material232 preferably comprises a spin-on-glass that is spin coated andhard-baked, e.g., at a temperature of about 350 degrees C. The secondinsulating material 232 is then lithographically patterned (treatment234) with small apertures 238 using a shrink method such as reflow,RELACS™ or CARL™. The first insulating material 230 is then removedusing thermal decomposition, at a temperature of about 400 degrees C. orgreater. This material selection is also advantageous in that the firstinsulating material 230 is carbonaceous, yet the second insulatingmaterial 232 is carbon-free, for example.

In a third material combination example, the first insulating material230 preferably comprises polynorbornene. The second insulating material232 preferably comprises a low k material with a sacrificial component236 comprising a high porogen content that decomposes at a temperaturelower than the decomposition temperature of the first insulatingmaterial 230. The second insulating material 232 may comprisepolypropylene or polyoxymethylene, as examples. A thermal treatment 234is then used to thermally remove the porogen sacrificial component 236,e.g., at a temperature of about 200 to 350 degrees C. The firstinsulating material 230 is then removed using thermal decomposition, ata temperature of about 400 degrees C. or greater. This materialselection is advantageous because the second insulating material 232comprises at least two components, wherein one component is thermallylabil.

In a fourth material combination example, the first insulating material230 preferably comprises NFC or BLACK DIAMOND™, as described in thefirst example. The second insulating material 232 preferably comprises asiloxane-organic co-polymer of moderate Si content, e.g., about 10 to20% Si. An O₂ plasma treatment 234 thermal treatment 234 is then used toconvert the second insulating material 232 into a porous semiconductormaterial 232′ having vertical channels or pores 238. The firstinsulating material 230 is then removed using O₂ plasma, and optionallyalso using heat assistance, e.g., by elevating the temperature to about100 to 300 degrees C. In this embodiment, the second insulating material232 may function as an inadequate bi-layer resist, for example.

In a fifth material combination example, the first insulating material230 preferably comprises polynorbornene. The second insulating material232 preferably comprises a siloxane-organic co-polymer of moderate Sicontent, e.g., about 10 to 20% Si. An O₂ plasma treatment 234 thermaltreatment 234 is then used to convert the second insulating material 232into a porous semiconductor material 232′ having vertical channels orpores 238. The first insulating material 230 is then removed usingthermal decomposition, at a temperature of about 400 degrees C. orgreater.

Note that the material combinations are included merely as example;alternatively, other materials and treatments may be used to form animpermeable second insulating material 232 over the first insulatingmaterial 230, convert the impermeable second insulating material 232 toa permeable insulating material 232′, and remove the first insulatingmaterial 230, forming air gaps 242 beneath the permeable insulatingmaterial 232′.

The optional barrier layer or liner (not shown in the figures) that maybe deposited before depositing the conductive material 210 of theconductive lines 210 protects the sidewalls of the conductive lines 210during the removal of the first insulating material 230, and also duringthe removal of the sacrificial portion 236 of the second insulatingmaterial 232, for example.

In some embodiments, preferably, all of the first insulating material230 is removed from beneath the second insulating material 232′, asshown in FIG. 11. This is advantageous because the lowest possibledielectric constant is achieved between the conductive lines 210.However, in other embodiments, a portion of the first insulatingmaterial 230 may remain beneath the second insulating material 232′, forexample (not shown in the figures). For example, the first conductivematerial 230 left remaining may reside on the bottom corners of theworkpiece 202/conductive line 210, the top surface of the workpiece 202,or the sidewalls of the conductive lines 210, as examples. Preferably,an air gap is formed in at least part of the area between the conductivelines 210 that was previously occupied by the first insulating material230, for example. Also, preferably, at least 80% of the first insulatingmaterial 230 is removed from beneath the second insulating material 232′in accordance with an embodiment of the present invention, forming anair gap 242 in at least 80% of the space between the conductive lines210, for example.

Note that preferably, the sacrificial portion 236 of the secondinsulating material 232 comprises a material with a decompositiontemperature that is lower than the decomposition temperature of thefirst insulating material 230 beneath the second insulating material232. This will prevent the first insulating material 230 from beginningto decompose before the second insulating material 232 is fullypermeable. Premature decomposition of the first insulating material 230may lead to lift-off of the second insulating material 232 or cracks inthe overall structure of the semiconductor device 200, for example.

Preferably, in some embodiments, after removing at least a portion ofthe first insulating material 230 to form the air gaps 242, themanufacturing of the semiconductor device 200 is then continued tocomplete the semiconductor device 200. For example, additionalinsulating and conductive material layers may be deposited over the topsurface of the conductive lines 210 and second insulating material 232′and patterned to form additional interconnect layers, not shown. Theembodiments of the invention described herein may be repeated on one ormore additional interconnect layers, for example. The pores or apertures238 of the second insulating material 232′ are preferably small enoughthat the subsequently deposited material layers will not enter into theair gaps 242 formed between the conductive lines 210 beneath the secondinsulating material 232′, in this embodiment.

In other embodiments, a cap layer 244 is preferably deposited over thetop surface of the conductive lines 210 and second insulating material232′, as shown in FIG. 11. The cap layer 244 preferably comprises aninsulating material. The cap layer 244 preferably comprises about 500Angstroms or less of SiCN, although alternatively, the cap layer 244 maycomprise other dimensions and materials, for example. The cap layer 244may comprise SiN or an oxide, for example, although if the cap layer 244comprises a high dielectric constant, preferably the cap layer 244 is asthin as possible, to avoid a large degradation in the effective k valueof the insulating material between the conductive lines 210. The caplayer 244 is preferably conformal and may be deposited by CVD, PVD, orother deposition methods, as examples, although the cap layer 244alternatively may be deposited by other methods.

The cap layer 244 preferably comprises an impermeable material so thatno contaminants or subsequently deposited material may enter through thepores 238 of the second insulating material 232 and enter the air gaps242, for example. The pores or apertures 238 of the second insulatingmaterial 232′ are preferably small enough such that, and the cap layer244 comprises a material such that, the cap layer 244 will not enterinto the air gaps 242 formed between the conductive lines 210 beneaththe second insulating material 232′. In some embodiments, for example,the second insulating material 232′ preferably comprises a relativelystructurally strong material, so that a thin cap layer 244 may be used,wherein the primary function of the thin cap layer 244 is to seal thepores or apertures 236 in the second insulating material 232′, thusminimally affecting the effective k value, for example.

The manufacturing of the semiconductor device 200 is then continued tocomplete the semiconductor device 200. For example, additionalinsulating and conductive material layers may be deposited over the topsurface of the cap layer 244 to form additional interconnect layers, notshown. Again, the embodiments of the invention described herein may berepeated in one or more additional interconnect layers of thesemiconductor device 200, for example.

FIGS. 12 and 13 show another embodiment of the present invention,wherein the air gaps 342 are formed in closely-spaced regions of aninterconnect layer, but not widely-spaced regions. Similar process flowsand materials are preferably used as were described with reference tothe embodiments shown in FIGS. 6 through 11. Similar reference numbersare designated for the various elements in FIGS. 12 and 13 as were usedin FIGS. 6 through 11. To avoid repetition, each reference number shownin FIGS. 12 and 13 is not described in detail herein. Rather, similarmaterials and thicknesses described for x02, x30, x32, etc. arepreferably used for the material layers shown as were described forFIGS. 6 through 11, where x=2 in FIGS. 6 through 11 and x=3 in FIGS. 12and 13.

In this embodiment, after the excess conductive material 210 is removedfrom the top surface of the second insulating material 232 (shown inFIGS. 7 and 8), yet before the treatment 234 is used to remove thesacrificial portion 236 of the second insulating material 232 (see FIG.8) one region of the workpiece 302, such as a portion of region 322 asshown in FIG. 12, is covered with a mask 350 before exposing the secondinsulating material 332 in other regions 320 to the treatment 334. Themask 350 may comprise a photoresist, hard mask, other materials, orcombination thereof, as examples. In this embodiment, after treating thesecond insulating material in regions 320 (and also portions of region322 not covered by the mask 350), the second insulating material 332′ ispermeable in the region 320 and portions of region 322, and the secondinsulating material 332 is impermeable in portions of region 322, asshown in FIG. 13. In this embodiment, preferably, at least a portion ofthe first insulating material 332 comprises removing at least a portionof the first insulating material 332 in some regions 320, but not otherregions (portions of region 322), of the workpiece 320. Air gaps 342 arethen formed beneath the permeable second insulating material 332′ byremoving at least a portion of the first insulating material 330 throughthe second insulating material 332′ in some regions 320 (and alsoportions of regions 322) but not in other regions, thus leaving thefirst insulating material 330 disposed beneath the impermeable secondinsulating material 332 in some regions 322, as shown.

In this embodiment, the conductive lines 310 may comprise widely-spacedconductive lines 310 in the region 322 of the workpiece 302 and air gaps342 formed between closely-spaced conductive lines 310 in region 320 ofthe workpiece 302, as shown in FIGS. 12 and 13. This is advantageousbecause the air gaps 342 are formed in areas where they are mostbeneficial, e.g., in region 320 having closely-spaced conductive lines310. However, in accordance with other embodiments of the presentinvention, alternatively, the conductive lines 310 in region 320 may becovered with a mask 350 during the treatment so that air gaps 342 areformed in region 322, for example, not shown. Alternatively, in someapplications it might be advantageous to form air gaps 342 in particularfunctional blocks of a semiconductor device 300 having a plurality ofvarious conductive line spacings (not shown), for example.

Referring again to FIG. 13, the region 320 having the air gaps 342 isnot necessarily much less structurally stable or strong as the portionof region 322 not having the air gaps 342 formed therein, because thedensity of the conductive lines 310 in region 320 is greater, thusproviding additional mechanical support to region 320, for example. Theportion of region 322 having the air gaps 342 formed therein may bemechanically strengthened by the use of a cap layer 244, as shown inFIG. 11, for example.

FIG. 14 shows another embodiment of the present invention, wherein anoptional conductive cap layer 460 is selectively formed on the topsurface of conductive lines 410. The optional conductive cap layer 460may be formed either before or after forming the air gaps 442. Again,similar reference numbers are designated for the various elements inFIG. 14 as were used in the previous figures, and to avoid repetition,each reference number shown in FIG. 14 is not described in detailherein.

In one embodiment, for example, the conductive cap layer 460 isselectively formed prior to forming the air gaps 442, to protect the topsurface of the conductive lines 410. In particular, the conductive caplayer 460 may be formed before treating the second insulating material438 to form the pores or apertures 438, because the RIE or othertreatment process may cause the top surface conductive lines 410 tooxidize or may otherwise deleteriously affect the top surface of theconductive lines 410, for example.

To form the optional cap layer 460, preferably a selective process isused to form the cap layer 460 only over the conductive lines 410, andnot over the second insulating layer 432′. The cap layer 460 maycomprise about 200 Angstroms or less of CoW, CoWP, or TaN, as examples,although alternatively, the cap layer 460 may comprise other dimensionsand materials. Cap layer 444 may then be deposited over cap layer 460and the second insulating material 432′, as shown.

Embodiments of the present invention may also be used to form air gapsin structures where the conductive lines are formed in a subtractiveetch process. For example, referring to FIG. 8, a workpiece 202 isprovided, and a layer of conductive material 210 is deposited over theentire surface of the workpiece 202. The conductive material 210 is thenpatterned and etched using lithography to form conductive lines 210. Thefirst insulating material 230 is deposited between the conductive lines210 and over the top surface of the workpiece 202, and the secondinsulating material 232 is deposited over the first insulating material230 between the conductive lines 210. The manufacturing process stepsdescribed with reference to FIGS. 8 through 11 are then continued asdescribed herein, altering the second insulating material 232 byremoving a sacrificial portion 236 of it (FIGS. 8 and 9), removing thefirst insulating material 230 through the second insulating material 232(FIG. 10) and forming air gaps 242 beneath the second insulatingmaterial 232′ (FIG. 11).

The conductive lines 210 may also be formed in a damascene process usinga sacrificial oxide layer, not shown. In this embodiment, a sacrificialoxide layer or other insulating material is deposited over the workpiece202, and the sacrificial oxide layer is patterned with the desiredpattern for the conductive lines 210. The conductive material 210 isdeposited over the patterned sacrificial oxide layer, and a CMP processis used to remove excess conductive material from the top surface of thesacrificial oxide layer and form the conductive lines 210. Thesacrificial oxide layer is then removed from between the conductivelines 120. Next, the first insulating material 230 is deposited over theconductive lines 210 and may be etched back to a predetermined height,exposing, for example, about ⅓ to ¼ of the top portions of theconductive lines 210. The second insulating material 232 is thendeposited over the first insulating material 230 and over the exposedtops of the conductive lines 210. A CMP process is used to remove excesssecond insulating material 232 from over the top surfaces of theconductive lines 210. The second insulating material 232 is then madepermeable using the treatment 234 comprising lithography or a thermaltreatment, as previously described herein. The first insulating material230 is then removed, and a thin cap layer may then optionally be formedon the top surfaces of the permeable second insulating material 232 andthe conductive lines 210.

Embodiments of the invention are particularly useful in multi-levelinterconnect structures. There may be 8, 9 or a dozen or moremetallization layers in an interconnect structure, for example. However,embodiments of the present invention are also useful in single levelinterconnect structures, for example.

Preferably, in some embodiments, the air gaps 242, 342, and 442described herein are formed between densely packed conductive lines 210,310, and 410 in order to reduce the RC delay of the interconnectstructure. For example, in a memory chip, air gaps 242, 342, and 442 arepreferably formed between the interconnect overlying the memory arraythat is densely packed (e.g., the conductive lines and spacestherebetween may comprise a minimum feature size of the chip), yet airgaps 242, 342, and 442 may not necessarily be formed in the interconnectregions of periphery circuits and support circuits, which may be lessdensely packed, although in some embodiments, air gaps 242, 342, and 442may also be formed in those regions. As another example, in amicroprocessor chip, in lower and/or intermediate levels of interconnect(e.g., the first through third metallization layers) that are denselypacked, air gaps 242, 342, and 442 are preferably formed betweenconductive lines, yet at higher or upper-most levels of interconnect,which are less densely packed, no air gaps 242, 342, and 442 may beformed.

Regardless of a particular application for an integrated circuit, airgaps 242, 342, and 442 may be formed in some regions of an interconnectlayer, providing an extremely low dielectric constant in those regions.Again, in some embodiments of the invention, as shown in FIGS. 12 and13, other regions of the same interconnect layer preferably have higherdielectric constant material 330 disposed between the conductive lines310 (e.g., in portions of region 322), which provides a more stablestructure, thus producing an overall interconnect structure that ismechanically stable and reliable.

Embodiments of the present invention are particularly beneficial forintegrated circuits that are application specific, that require a highperformance BEOL and low RC delay, and that utilize copper as thematerial for the conductive lines, for example. Embodiments of theinvention may be implemented in applications such as microprocessors,game station integrated circuits, and cell phone integrated circuits, asexamples, although the invention may be used in other types ofintegrated circuits. However, embodiments of the present invention arealso useful in other applications, having fewer metallization layers andutilizing aluminum as the material for the conductive lines, forexample.

Advantages of embodiments of the invention include forming air gaps 242,342, and 442, achieving a low dielectric constant between conductivelines 210, 310, and 410. Because the majority of the space betweenconductive lines 210, 310, and 410 comprises the air gaps 242, 342, and442, a dielectric constant of about 2.2 or lower between the conductivelines 210, 310, and 410 is achievable.

Advantages of preferred embodiment of the present invention includeproviding novel methods of forming air gaps 242, 342, and 442 betweenconductive features 210, 310 and 410. Air gaps 242, 342, and 442 havinga predictable shape and a predetermined height over a wide range ofspaces are created. No additional topography is introduced to thesemiconductor devices 200, 300, and 400, and few additional processingsteps are required.

In some embodiments, air gaps 242, 342, and 442 are formed betweenconductive features 210, 310, and 410 in critical areas, but not innon-critical areas, where the RC delay is not an issue. Because someregions of the workpiece 202, 302, and 402 do not have the air gaps 242,342, and 442 disposed therein, the insulating material 330 in thoseregions provides strong structural support and mechanical strength forthe integrated circuit. Advantageously, air gaps 242, 342, and 442 maybe formed in some regions but not others, while maintaining theplanarity of the topography of the layer of interconnect/ILD.

The top layer of insulating material 232, 332 and 432 having thesacrificial portion 236 is impermeable as deposited, preventingcontamination of the various material layers (e.g., underlying materiallayers and also the insulating material layer 232, 332, and 432 itself)during a chemical-mechanical polish procedure to remove excessiveconductive material from the top surface of the top layer of insulatingmaterial 232, 332 and 432, while forming the conductive lines 210, 310,410 in a damascene process.

Although embodiments of the present invention and their advantages havebeen described in detail, it should be understood that various changes,substitutions and alterations can be made herein without departing fromthe spirit and scope of the invention as defined by the appended claims.For example, it will be readily understood by those skilled in the artthat many of the features, functions, processes, and materials describedherein may be varied while remaining within the scope of the presentinvention. Moreover, the scope of the present application is notintended to be limited to the particular embodiments of the process,machine, manufacture, composition of matter, means, methods and stepsdescribed in the specification. As one of ordinary skill in the art willreadily appreciate from the disclosure of the present invention,processes, machines, manufacture, compositions of matter, means,methods, or steps, presently existing or later to be developed, thatperform substantially the same function or achieve substantially thesame result as the corresponding embodiments described herein may beutilized according to the present invention. Accordingly, the appendedclaims are intended to include within their scope such processes,machines, manufacture, compositions of matter, means, methods, or steps.

1. A semiconductor device, comprising: a workpiece, the workpiececomprising a first region and a second region; a plurality of conductivelines formed over the workpiece, the plurality of conductive lineshaving a top region; a first insulating material disposed between theplurality of conductive lines and proximate the top region of theplurality of conductive lines, the first insulating material beingimpermeable in the first region and permeable in the second region; asecond insulating material disposed beneath the first insulatingmaterial between the plurality of conductive lines in the first region;and air gaps disposed beneath the first insulating material between theplurality of conductive lines in the second region.
 2. The semiconductordevice according to claim 1, wherein the plurality of conductive linescomprises widely-spaced conductive lines in the first region of theworkpiece and closely-spaced conductive lines in the second region ofthe workpiece, or wherein the plurality of conductive lines comprisesclosely-spaced conductive lines in the first region of the workpiece andwidely-spaced conductive lines in the second region of the workpiece. 3.The semiconductor device according to claim 1, further comprising afirst cap layer disposed over the first insulating material and theplurality of conductive lines, the first cap layer comprising aninsulating material.
 4. The semiconductor device according to claim 3,further comprising a second cap layer disposed over the plurality ofconductive lines beneath the first cap layer, the second cap layercomprising a conductive material.
 5. The semiconductor device accordingto claim 1, wherein a thickness of the first insulating materialcomprises 34-25% of a thickness of the conductive lines and a thicknessof the second insulating material comprises 66-75% of the thickness ofthe conductive lines.
 6. The semiconductor device according to claim 1,wherein the first insulating material comprises a material with adecombustion temperature that is lower than a decombustion temperatureof the second insulating material.
 7. The semiconductor device accordingto claim 1 further comprising a barrier layer over sidewalls of theplurality of conductive lines.
 8. A semiconductor device, comprising: aplurality of conductive lines formed over a workpiece, the workpiecehaving a first region and a second region, the plurality of conductivelines having a top region; a first insulating material comprising twocomponents wherein one component is thermally labile, the firstinsulating material disposed between the plurality of conductive linesand proximate the top region, the first insulating material beingimpermeable in the first region and permeable in the second region; asecond insulating material in the first region, the second insulatingmaterial comprising polynorbornene disposed beneath the first insulatingmaterial, wherein a decombustion temperature of the thermally labilecomponent is lower than a decombustion temperature of the secondinsulating material; and air gaps disposed beneath the first insulatingmaterial between the plurality of first conductive lines in the secondregion.
 9. The semiconductor device according to claim 8, wherein afirst cap layer is formed over the top region of the conductive lines.10. The semiconductor device according to claim 9, wherein a second caplayer is formed over the first cap layer and the first insulatingmaterial.
 11. A semiconductor device, comprising: a plurality ofconductive lines formed over a workpiece, the workpiece having a firstregion and a second region, the plurality of first conductive lineshaving a top region; a first insulating material comprisingsiloxane-organic co-polymere with about 10-20% Si content, the firstinsulating material being impermeable in the first region and permeablein the second region; a second insulating material in the first region,the second insulating material comprising polynorbornene disposedbeneath the first insulating material; and air gaps disposed beneath thefirst insulating material between the plurality of first conductivelines in the second region.
 12. The semiconductor device according toclaim 11, wherein a first cap layer is formed over the top region of theconductive lines.
 13. The semiconductor device according to claim 12,wherein a second cap layer is formed over the first cap layer and thefirst insulating material.
 14. The semiconductor device according toclaim 1, wherein the first insulating material comprises a spin-on glassand the second insulating material comprises non-photosensitive finechemicals.
 15. The semiconductor device according to claim 1, whereinthe first insulating material comprises a spin-on glass and the secondinsulating material comprises polynorbornene.
 16. The semiconductordevice according to claim 1, wherein the first insulating materialcomprises a low-k material with a sacrificial component having a highporogen content and the second insulating material comprisespolynorbornene.
 17. The semiconductor device according to claim 1,wherein the first insulating material comprises a siloxane-organicco-polymer of about 10-20% Si and the second insulating materialcomprises non-photosensitive fine chemicals.
 18. The semiconductordevice according to claim 1, wherein the first insulating materialcomprises a siloxane-organic co-polymer of about 10-20% Si and thesecond insulating material comprises polynorbornene.
 19. Thesemiconductor device according to claim 3, wherein the first cap layeris selected from the group of SiCN, SiN and an oxide.
 20. Thesemiconductor device according to claim 4, wherein the second cap layeris selected from the group consisting of CoW, CoWP and TaN.